TEKSTİL VE KONFEKSİYON

Vol: 29, No.: 2 DOI: 10.32710/tekstilvekonfeksiyon.475490

Improvement of Multifunctional Automotive Textile

Zeynep Ömeroğulları Başyiğit *

Uşak University, Faculty of Engineering, Textile Engineering Department, Uşak, Turkey

Corresponding Author: Zeynep Ömeroğulları Başyiğit, [email protected]

ABSTRACT ARTICLE HISTORY In order to improve multifunctional automotive textile, required functionalities that have been expected by the automotive industry were enhanced in this study. For this aim, flame retardant and water-oil Received: 28.10.2018 repellent effects were achieved on 100 % polyester based automotive fabrics via pad-dry-cure system Accepted: 27.03.2019 with performed finishing recipes. After functionalization of the fabrics, polyurethane based foams were laminated to the treated automotive textiles. In order to be able to compare the results of tests and to determine the effects of used chemicals on the functionalities of fabrics, chemical amounts of recipe were optimized and the results were discussed. Flame retardancy, water repellency and oil repellency tests were performed before and after abrasion tests. Color spectrums of treated fabrics were tested after chemical finishing applications. Morphological analyses of samples were tested by SEM and chemical structures of the fabrics were analyzed by FTIR-ATR. According to performance test results, KEYWORDS multifunctional automotive textile including flame retardant and water-oil repellent effect was achieved successfully. During the burning test, it was determined that laminated textile structure was self- Automotive textile, flame retardant, water-oil repellent, extinguished whereas 3M water repellency grades were at the highest value before abrasion tests. chemical finishing application

1. INTRODUCTION used in the manufacturing processes [4-6]. Car seat fabric requires considerable technical input to produce both the Automotive textiles have one of the most valuable world aesthetic and also very demanding requirements such as markets for technical textiles and there is a broad spectrum reduced flammability, abrasion resistance, resistance to of products comprising novel textile structures and high sunlight, soil resistance and UV degradation [2,7]. Since quality design. Automotive technical textiles include wide seat covers cannot be washed in washing machine, these range of materials such as upholstery and seating, floor must show strong soil masking behavior [1,8]. The design covering trunk liners, headliners door and side-panel and performance properties of technical textiles present in coverings, pillar coverings as well as safety belts, airbags, automotive interiors are among the most important criteria thermal and sound insulators, tyres and textile-reinforced for consumer satisfaction and this design and performance flexible and hard composites. The textiles for interior criteria could be varied according to consumer’s furnishings are primarily made of woven, warp knitted, weft requirement [1,2]. knitted, laminated fabrics and nonwovens [1-3]. Automobile seat upholstery generally includes multi- The requirements for textile structures used in automotives component structures. The seat covering is composed of are different from those used in clothing and other foam cushion mostly made up of polyurethane, for the seat applications. The performance of the automotive textiles, back and bottom and a trim component including a face which constitute approximately 20-25 kg in a car, depends material, predominantly a polyester fabric, foam backing, on the fibre properties, fabric structures and various finishes mostly made up of polyurethane and a reinforcing scrim

To cite this article: Ömeroğulları Başyiğit, Z. 2019. Improvement of multifunctional automotive textile. Tekstil ve Konfeksiyon. 29(2), 113-120.

TEKSTİL ve KONFEKSİYON 29(2), 2019 113 material, generally polyamide knitted fabric. On the top Nowadays, when compared to mono-functional textiles, the surface, weaved or knitted textile fabric can be used as well request for multifunctional textile materials has been [3,9]. Polyurethane based foams which exist under the top increased especially in the automotive textile industry. Since surface layer, are laminated to the fabric in various ways [3, the goal of the finishing operations undertaken by upholstery 10-15]. Laminated polyurethane foams provide comfortable manufacturers is the same “to bestow fabrics with particular feeling and prevent the wrinkling of the top surface. Usually aesthetic and functional qualities”, multifunctional the bottom layer of the assembly is furnished with a knitted, automotive textile was improved in this study. Flame nonwoven, or film backing, to impart dimensional stability retardant and water-oil repellent effects were achieved on and prevent excessive foam wear. Over many years, these 100% polyester based automotive upholstery fabrics via layers have been combined on a large scale by flame pad-dry-cure system with performed finishing recipes. After lamination (Fig.1), since ample production rates and low functionalization of the fabrics, polyurethane based foams cost have ensured good returns to processors [16,17]. were laminated to the treated automotive fabrics. According to the performance tests results, flame retardant and water- oil repellent effect was achieved successfully and it was determined that laminated textile structure showed self- extinguishing behavior whereas 3M water repellency grades were at the highest value before abrasion tests.

2. EXPERIMENTAL DETAILS

2.1 Material

100% polyester double-face knitted fabrics with two different densities (36 wales x 22 courses, 50 g/m2) and (28 wales x 22 courses, 40 g/m2) and polyurethane based foams (density with 32 g/m3) were supplied by Martur Company (Turkey). Polyethylene based softener was taken from Tanatex (Turkey) and fluoroalkyl acrylate copolymer was gently supplied by Daikin America, NY, USA while nitrogen containing phosphonic acid salt as a flame retardant agent and Invadine PBN as an anionic surfactant were purchased

from Huntsman Textile Effects (Charlotte, USA). CaCO3 based non-durable flame retardant agent was gently supplied by Kale Natural and anionic surfactant was added into the finishing bath as a wetting agent.

2.2 Method Figure 1. Flame lamination [10] 100% polyester double-face knitted fabrics with two different In flame lamination, a layer of foam is exposed to an open densities were used in this study. Both fabrics were flame at around 950 C which causes its uppermost surface generally used as transportation upholstery fabrics in the to melt. While the foam is molten, it is fed into an textile market. The dyeing procedure was carried out with arrangement of nip rollers which presses an incoming layer disperse dyestuff Foron Black AS-3LF in HT conditions. Two of fabric onto its surface, as depicted in Fig. 1. When the chemical finishing recipes were used in pad-dry-cure system laminate has cooled, strong chemical bonds develop (Mathis VFM, vertical padder and Mathis oven PTE-B) for between the adjacent layers [3,10,12,16]. this study in order to optimize the amounts and to determine the effects of chemical agents on the functionalities of the For the upholstery fabrics with improved functional textile structures. In order to improve the flame retardancy characteristics, the selection of the top surface fabric is and water-oil repellency effect of upholstery fabrics, 200 g/L important as well as the selection of functionalities that are nitrogen containing phosphonic acid salt, 5 g/L anionic to be applied on. The volume of upholstery fabric used per 2 surfactant, 20 g/L polyethylene based softener and 80 g/L vehicle varies by region however an average 5-6 m of fluoroalkyl acrylate copolymer were used in both recipes of fabric are used in cars for upholstery [6]. It should be also finishing process. In recipe 1, while 125 g/L CaCO3 based emphasized that warp-knitting sector has broadened its chemical solution was added into the bath, in the second market base and especially has expanded into automotive recipe, this amount was used as 200 g/L. After applying all industry [1-3]. Due to its significant mechanical primary and auxiliary chemicals in padding bath with a wet performance, polyester has been established as the most pick- up ratio as 85%, the fabrics were dried at 11 °C for 1-2 popular fibre for automotive textiles. On the whole, polyester min, and then cured at 145 °C for 2 min. The knitted fibre provides good mechanical performance including good polyester fabrics which had multifunctional finishing abrasion resistance, high dimensional stability, excellent application were laminated with polyurethane foams in flame resistance to photo-oxidative degradation, and high light laminator (Mario Crosta). All fabrics were laminated with fastness [16]. flame lamination method in speed of 30 m/min. Codes of treated fabrics were shown in Table 1 below.

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Table 1. Codes of samples

Codes of samples Explanation 2 UF1 Untreated 50 g/m polyester fabric 2 UF2 Untreated 40 g/m polyester fabric 2 F1A 50 g/m polyester fabric that treated with recipe 1 2 F2A 40 g/m polyester fabric that treated with recipe 1 2 F1B 50 g/m polyester fabric that treated with recipe 2 2 F2B 40 g/m polyester fabric that treated with recipe 2 2 LF1A Laminated textile composite material that included 50 g/m polyester fabric which treated with recipe 1 2 LF2A Laminated textile composite material that included 40 g/m polyester fabric which treated with recipe 1 2 LF1B Laminated textile composite material that included 50 g/m polyester fabric which treated with recipe 2 2 LF2B Laminated textile composite material that included 40 g/m polyester fabric which treated with recipe 2

2.3 Flame Retardancy Test (ISO 3795) smooth, horizontal surface. 3 small droplets which consisted of water/alcohol were placed onto the sample using a Flame retardant effects of samples were tested according to pipette. The droplets were observed for 10 s. When after 10 ISO 3795. This test was used for determining the horizontal s, 2 of the 3 droplets were still visible as spherical to burning rate of textile composite structures used in the road hemispherical, the fabric passed the test. Samples were vehicles (for example, passenger cars, lorries/trucks, estate rated as pass or fail of the appropriate test liquid, W – 10. cars, coaches), and of tractors and machinery for agriculture Standard test liquids using in this test were shown in Table and forestry [18]. The sample, held horizontally in a U- 2 [19]. shaped holder, was exposed to the flame for 15 s in a combustion chamber as showed in Fig. 2. The test determined if and when the flame extinguished or the time in which the flame passed a measured distance.

B = 60 x (D/T) (1) where, B is the burn rate in millimeters per minute, D the length the flame travels in millimeters and T the time in seconds for the flame to travel D millimeters.

2.4 3M Water Repellency Test Method

Water repellent effects of samples were tested according to 3M Water Repellency Test Method. According to 3M water Figure 2. Standard of ISO 3795 [18] repellency test method the samples were placed flat on a

Table 2. Standard test liquids for 3M water repellency test method

3M Water Repellency Rating Number Composition of Test Liquid

W Water 1 90/10 Water/2-Propanol 2 80/20 Water/2-Propanol 3 70/30 Water/2-Propanol 4 60/40 Water/2-Propanol 5 50/50 Water/2-Propanol 6 40/60 Water/2-Propanol 7 30/70 Water/2-Propanol 8 20/80 Water/2-Propanol 9 10/90 Water/2-Propanol 10 2-Propanol

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2.5 3M Oil-Repellency Test Method structure was burned totally with the burning rate of 156 mm/min. It should be noted here that automotive industries Oil repellent effects of samples were tested according to 3M generally uses market chemicals in one-step finishing Oil Repellency Test Method. According to 3M oil repellency process in order to achieve multifunctional upholstery fabric test methods, the samples were placed flat on a smooth, such as flame retardant and water-oil repellent at the same horizontal surface. Small droplets were placed onto the time but they reported from their laboratory studies that sample using a pipette. The droplets were observed for 30 s when fluorocarbon based chemicals were added into from a 45o angle. When the droplet neither wetted the phosphonic acid salt baths, the burning rate of the textile fabric, nor had any sign of wicking, the test was repeated composites was over 100 mm/min which could not be using the next numbered oil. This was continued until an oil accepted by the car producers. So here in this study, it was sample was found to either wet the fabric or show wicking. considered that increasing the amount of phosphonic acid The oil repellency rating was deemed to be the highest salt in the bath would not make a positive change on FR numbered test oil which did not wet the fabric within 30 s. effect when using fluorocarbon based chemicals in the Standard test liquids for this test were shown in Table 3 [19]. same bath in one-step finishing processes. That’s why; calcium carbonate based FR agent was added into the bath Table 3. Standard test liquids for 3M oil repellency test method in order to determine the burning behavior of textile composites. As it was shown in Fig. 3, the burning rates of treated textile composites decreased significantly when 3M oil repellency Composition of test liquid rating number compared to untreated ones. It was considered that endothermic decomposition reactions of calcium carbonate 1 Liquid paraffin provided heat sink on the fibers that combustion was 2 65/35 liquid paraffin /n-hexadecane retarded [20,21]. This flame retardant effect was more 3 n-hexadecane significant when the amount of calcium carbonate based 4 n-tetradecane chemical was increased. If the treated textile composites 5 n-dodecane were compared to each other, it could be clearly seen that 6 n-decane LF1A and LF1B had better flame retardant effect than LF2A 7 n-octane and LF2B which was contributed to the effect of density 8 n-heptane properties on burning behavior of fabrics. It was observed that when the density of the fabric was increased, flame 2.6 Color Spectrum Analysis retardant effect was improved because of decreasing the air gaps between the yarns which were responsible for carrying CIE L*, a*, b* and ∆E values of untreated and treated oxygen that caused inflammation. polyester fabrics were investigated by GretagMacbeth-7000 A Spectrophotometer. 3.2 3M Water and Oil Repellency Test Results

2.7 Scanning Electron Microscope (SEM) Test 3M water and oil repellency test results of were shown in Table 4 and Table 5, respectively. As seen in Table 4, water The surface morphology of untreated and treated polyester repellency grades were at the highest rate or around 10 fabrics were scanned by a ZEISS/EVO 40 electron whereas the oil repellency rates were around 6-5. It was microscope at 10kV under a high vacuum at x1500 considered that fluoroalkyl acrylate copolymer provided magnification after being coated with gold-palladium (Au-Pl) excellent water repellent effect and good oil repellent effect at a thickness of 40–50nm by a BAL-TEC SCD 005 coating on polyester fabrics whereas untreated samples did not device. show any water or oil repellent effect. When the amount of calcium carbonate was increased, it was indicated that 2.8 Fourier Transform Infrared (Attenuated Total water repellency effect decreased slightly. This result was Reflectance) Spectra FTIR-ATR analysis attributed to the water absorption effect of calcium FT-IR ATR spectra of the untreated and treated polyester carbonate that showed either when used in composite fabrics were investigated by a Thermo Nicolet 6700 device materials [22] or used in finishing bath of textile materials in a wave number range of 525–4000 cm-1. such as polyester and cotton [23,24]. However, after 20000 cycle abrasion tests, both water and oil repellency rates were decreased. It was considered that these results were obtained because of abrasion and removing of non-durable 3. RESULTS AND DISCUSSION finishing agents on the surface of the fibers with the friction 3.1 Flame Retardancy Tests Results (ISO 3795) movement of the load used in abrasion test device.

Burning rates of laminated textile composite materials were shown in Fig.3 according to standard of ISO 3795. As it was seen below, flame retardant effect of the composite was increased significantly while untreated textile composite

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ISO3795 Burning Rate mm/min

40

35

30

25

20 ISO3795 Burning Rate mm/min 15

10

5

0 LF1A LF2A LF1B LF2B

Figure 3. Burning rates of laminated textile composites after finishing process

Table 4. 3M water repellency test results

Samples 3M water repellency test grades After abrasion test (Martindale) 20000 cycle F1A 10.5 7 F2A 10 6 F1B 10 6.5 F2B 9.5 5

Table 5. 3M oil repellency test results

Samples 3M oil repellency test grades After abrasion test (Martindale) 20000 cycle F1A 6.5 5.5 F2A 5 4.5 F1B 6.5 5.5 F2B 5.5 4

3.3 Color Spectrum Analysis Results on knitted polyester fabrics. For both color spectrum analysis results (Table 6 and Table 7), it was indicated that Color spectrum analysis of treated polyester fabrics were when the amount of CaCO shown in Table 6 and Table 7. It was determined according 3 was increased in the recipe, ∆E to the color spectrum results that, ∆E values of all treated values increased slightly. For the first recipe, it was fabrics were around 1.00 which considered as these concluded that ∆E values did not even reach 1.00 after finishing applications did not cause significant color changes application of both polyester fabrics.

Table 6. Color spectrum analysis of F1A and F1B

Samples CIE L* a* b* Values L* a* b* ∆E UF1 17.15 0.13 -0.38 - F1B 15.92 0.13 -0.09 1.22 F1A 16.44 0.13 -0.14 0.75

Table 7. Color spectrum analysis of F2A and F2B

Samples CIE L* a* b* Values L* a* b* ∆E UF2 18.35 0.11 -0.49 - F2B 17.41 0.16 -0.13 1.00 F2A 17.35 0.09 -0.24 0.96

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3.4 Scanning Electron Microscope (SEM) Results peaks of the polyester which were seen at 1715 cm-1 (carbonyl C=O tension vibration), 1242 cm-1 (aromatic ester SEM micrographs at x1500 magnification of untreated -1 C–C–O tension vibration) and 1096 cm (aromatic ester O– polyester fabrics and fabrics treated with recipe 1, were C–C tension vibration) [23]. Figure 5 also gave the detail shown in Fig. 4. In order to observe the chemical particles about bonding of phosphonic acid salt based flame easily in the micrographs, polyester fabrics treated with retardant agent to the polyester fabric. In the spectra of FB1, recipe 2 which had increased amount of FR agent, was since the wave number range of the P–O–R vibration was selected for microscope analysis. According to the SEM generally seen between the range of 1100–950 cm-1, an results, it was determined that clean and smooth surfaces interaction of flame retardant agent with the polyester fabric were seen in Figs. 4a and 4c whereas some chemical could be observed at 1056 cm-1 which occurred a vibration particles and residues were indicated on the polyester yarn differently from untreated fabric. Additionally, the peak of the surfaces after finishing applications as shown in Figs. 4b P=O vibration could be indicated between the range of and 4d. 1350-1150 cm-1 [25] for the treated fabric which could be attributed to phosphonic acid salt based FR agent that was 3.5 Fourier Transform Infrared (Attenuated Total used in this study. When the calcium carbonate based FR Reflectance) Spectra FTIR-ATR Analysis Results agent was investigated in the spectra, it could be mentioned FTIR-ATR analysis of untreated 50 g/m2 polyester fabric that any characteristic peaks of CaCO3 could be seen in the (UF1) and 50 g/m2 polyester fabric that treated with recipe 2 spectra expect the vibrations occurred around the range of -1 (F1B) were shown in Fig. 5. Here, in order to be able to water peaks of substances, 3200-2800 cm which was capture the certain peaks in this analysis, recipe 2 which considered as it was occurred because of the water was consisted of most increased amount of chemical absorption characteristic of calcium carbonate based FR agents, was selected. This figure indicated the characteristic agent [26].

a). UF1 b). F1B

c). UF2 d). F2B

2 2 2 Figure 4. SEM results of a) untreated 50 g/m polyester fabric b) 50 g/m polyester fabric that treated with recipe 2 c) untreated 40 g/m polyester fabric d) 40 g/m2 polyester fabric that treated with recipe 2

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A%

Figure 5. FTIR-ATR analysis results of UF1 and F1B

4. CONCLUSION contributed to the effect of density properties on burning behavior of fabrics. It was indicated that fluoroalkyl acrylate Since the request for multifunctional textile materials was copolymer provided excellent water repellent effect and increased especially in the automotive textile industry, in this good oil repellent effect on polyester fabrics while untreated study flame retardant and water-oil repellent automotive samples did not show any water or oil repellent effect. textiles were improved to fulfill this demand of industry. For Characterization tests were carried out, untreated and this aim 100% polyester knitted automotive fabrics applied treated samples were compared to each other and finishing with flame retardant and water-oil repellent agents in pad- chemicals were indicated on the surface of the treated dry-cure system with performed finishing recipes. After fabrics in SEM test whereas characteristic and functional functionalization of the fabrics, polyurethane based foams chemical bond peaks were captured in FTIR-ATR analysis. were laminated to the treated automotive textiles. According It was considered that the recipes used in this study could to the flame retardancy test (ISO 3795), the flame retardant serve as a model of finishing applications for improving effect of laminated textile composites were increased multifunctional textile structures in automotive industry. significantly. Burning rates of them were in the range 19- 33.5 mm/min. It was concluded that flame retardant effect Acknowledgement was more significant when the amount of calcium carbonate based chemical was increased in the finishing recipe. When The author of this study is grateful to Birlik Yün İplik the treated textile composites were also compared to each Company and Microscopy Laboratory of Department of other, it was determined that LF1A and LF1B had better Physics of Faculty of Arts and Science, Uludag University, flame retardant effect than LF2A and LF2B which was for their kind support.

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